Device for winding a multipole stator

ABSTRACT

A device ( 10 ) for winding wire around pole horns of a rotationally symmetrical multipole stator ( 12 ) of an electrical machine has a wire guide for the supply of the wire and for performing a winding movement made up of individual movements around the pole horn and a traversing movement in the longitudinal direction of the pole horn. To perform a first traversing movement in a first direction (z) the wire guide is actively connected to a winding rod ( 60 ) which is axially movable in the first direction (z), to perform a second traversing or rotational movement in a second direction an indexing device is actively connected to the stator ( 12 ) to be wound, and to perform the traversing movement in a third direction (x) corresponding to the longitudinal direction of the pole horn to be wound, the wire guide is connected to a bracket ( 32 ) which is movable in the third direction (x).

BACKGROUND OF THE INVENTION

[0001] The invention relates to a device for winding wire around pole horns of a rotationally symmetrical multipole stator of an electrical machine, with a wire guide for the supply of the wire and for performing a winding movement made up of individual movements around the pole horn to be wound and a traversing movement in the longitudinal direction of the pole horn.

[0002] In automotive engineering, electronic motors are increasingly replacing the commutator motors that were common in the past. A distinction is made between internal and external rotor motors, depending upon design. The laminations of the stator of an internal rotor motor approximately correspond to the laminations of an asynchronous motor. The laminations of the stator of an external rotor motor largely correspond to the armature laminations of a commutator motor.

[0003] For a stator of an internal or external rotor motor it is desirable to apply a winding that is distributed uniformly over the entire length of each pole horn, preferably in layers.

[0004] A winding device which is common today has a winding rod in the form of a hollow shaft, which has one or more wire guide nozzles fitted on the end at right angles. The winding rod is controlled such that the wire guide nozzles plus the emerging winding wire perform a stroke movement and the stator performs a swivel movement of approximately one pole pitch. As a result the wire is guided in an approximately right-angled winding track around the pole horn in question.

[0005] To prevent the winding from piling up at one point, an additional movement of the wire guide nozzles to-and-fro in the radial direction is required.

[0006] A device of the type mentioned above is disclosed in EP-A1 076 401. However, the winding device described therein is a complicated construction.

[0007] The invention relates to the task of creating a device of the type mentioned above, the design of which is as simple as possible, which can be converted in a simple manner, and which is suitable for the simultaneous winding of either several pole horns of a single stator or one pole horn each of several stators. In addition, the device should be equally suitable for the winding of stators for internal and external rotor motors.

SUMMARY OF THE INVENTION

[0008] The task according to the invention is solved in that:

[0009] to perform a first traversing movement in a first direction, the wire guide is actively connected to a winding rod which is axially movable in the first direction,

[0010] to perform a second traversing or rotational movement in a second direction, an indexing device is actively connected to the stator to be wound, and

[0011] to perform the traversing movement in a third direction corresponding to the longitudinal direction of the pole horn to be wound, the wire guide is connected to a bracket which is movable in the third direction.

[0012] The bracket should preferably be movable in the third direction by means of a second guide, where preferably a first threaded spindle is provided to perform the traversing movement. This first threaded spindle is preferably connected to a first drive motor by means of a flexible shaft.

[0013] The bracket is suitably fastened to an adjusting block which is movable along the second guide, whereby the bracket is preferably movable in the first direction along a first guide located on the adjusting block, and the first threaded spindle engages the adjusting block.

[0014] In a preferred variant of the device according to the invention a mounting piece with a slot lying in the third direction is arranged on the winding rod and a guide pin which is attached to the bracket is guided in the slot.

[0015] The winding rod is preferably connected to a second drive motor by way of a second threaded spindle.

[0016] During the winding process the indexing device is preferably connected to a clamping device for the stator to be wound.

[0017] For the simultaneous winding of several pole horns of a single stator or one pole horn each of several stators, several brackets are arranged each with a wire guide, the winding rod engages each of the brackets and the brackets can be moved synchronously by means of a first common drive motor.

[0018] For the simultaneous winding of one pole horn each of several stators the brackets with the wire guide are preferably arranged parallel to each other and in line.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Further advantages, features and details of the invention are given in the following description of preferred embodiment examples and also in the drawing; the drawings show diagrammatically:

[0020]FIG. 1 a diagonal view of a winding machine;

[0021]FIG. 2 a diagonal view of a detail of FIG. 1;

[0022]FIG. 3 an enlarged side view of an adjusting unit for a wire guide nozzle of FIG. 1

[0023]FIG. 4 a diagonal view of the winding machine of FIG. 1 with a pallet transport unit;

[0024]FIG. 5 a side view of a detail of FIG. 4;

[0025]FIG. 6 a view from below of a detail of FIG. 1;

[0026]FIGS. 7, 8 the relative movements of a wire guide nozzle during a winding operation.

DETAILED DESCRIPTION

[0027] A winding machine 10 shown in FIGS. 1 to 8 is intended for the winding of multipole stators 12. The stator 12 shown in FIG. 6 for example consists primarily of an annular body 14 with pole horns 16 protruding radially inwards from this and separated from each other by intermediate spaces in the form of axial grooves 18. Three windings 20 have already been completed. The 15-pole stator 12 shown as an example is part of an internal rotor electronic motor. The stator 12 is produced by the stamp packing of identical laminations to form a laminated core.

[0028] As can be seen from FIG. 5, the stator 12 is fixed in a clamping device 22 during the winding process. A shaft 26 rotatably mounted in a transport pallet 24 is rigidly connected to a collet chuck 22. In the winding position the free end of the shaft 26 is connected to an indexing device 28 by way of a carrier 30. The indexing device 28 serves to perform a rotational movement of the stator 12 about its rotational axis z. The transport pallet 24 is guided to and from the winding machine 10 by way of a pallet conveyor 84 by means of conveyor belts 82.

[0029] A bracket 32 for a wire guide nozzle 34 is slidably mounted in a first guide rail 40 arranged vertically, parallel to the rotational axis z of the stator 12. The wire guide nozzle 34 is fastened at the lower end of the bracket 32 and points radially outwards in relation to the stator 12 and its rotational axis z. The upper part of the bracket 32 is formed as a wire guide tube 38. The winding wire 36 is fed by way of the wire guide tube 38 of the wire guide nozzle 34.

[0030] The first guide rail 40 is part of an adjusting block 42, which can be moved on a second fixed-position guide rail 44 in a horizontal traversing axis x in the direction of the vertical axis z, which corresponds to the rotational axis of the stator. The adjusting block 42 is movable on the first guide rail 40 by means of a first threaded spindle 46 located in a thread 48 in the adjusting block 42. The first threaded spindle 46 is connected by way of a deflection gear 50 to a flexible shaft 52 located in a covering 54.

[0031] In the embodiment example shown, three of the units described above for the simultaneous winding of three pole horns 16 of a stator 12 are arranged symmetrically at an angle of 120° in relation to one another. Each of the flexible shafts 52 (only one flexible shaft is shown in the drawing) is connected to a central first drive motor 56.

[0032] A winding rod 60 which is movable along the vertical axis z is mounted in a pillow block 58. For the performance of stroke movements in the direction of the z axis, the upper end of winding rod 60 is formed as a second threaded spindle 62 which is connected to a second drive motor to perform the stroke movements of the winding rod 60.

[0033] Horizontally protruding mounting pieces 66 with a slot also running in the horizontal direction are located at the lower end of winding rod 60. The slot 68 serves to hold guide pins 70 mounted on the side of the bracket 32. By means of this arrangement of the mounting pieces 66, a stroke movement of the winding rod 60 is simultaneously transmitted to all three brackets 32, leading to a synchronization of the stroke movements of all wire guide nozzles 34.

[0034] The second guide rails 44 for the adjusting blocks 42 are mounted on a first platform 72. This platform 72 has a central opening 73. The first guide rails 40 and the brackets 32 which slide along these protrude through the opening 73. The two drive motors 56, 64 are mounted on a second platform 74 arranged above the first platform 72. The two platforms 72, 74 are held at a distance from one another by a back wall 76 on which is arranged the pillow block 58 for the winding rod 60. The arrangement consisting of the two platforms 72, 74 and the back wall 76 is fastened to a mounting wall 80 such that it is movable in the vertical direction by means of third guide rails 75.

[0035] As shown in FIG. 7, the wire 36 is wound by an approximately rectangular movement of the wire guide nozzle 34 around the pole horn 16 to be wound. The wire guide nozzle 34 is controlled by the stroke movements of the winding rod 60 and the indexing movements of the indexing device 28 each by a pole pitch n. The movement sequence of the wire guide nozzle 34 for applying a winding loop around the pole horn 16 is made up of the following individual sequential movements:

[0036] first stroke movement h1 vertically upwards, performed by a corresponding stroke movement of the winding rod 60

[0037] first indexing movement e1 in the horizontal direction, performed by a corresponding indexing movement of the indexing device 28 in its direction of rotation

[0038] second stroke movement h2 vertically downwards, performed by a corresponding stroke movement of the winding rod 60

[0039] second indexing movement e2 in the opposite horizontal direction, performed by a corresponding indexing movement of the indexing device 28.

[0040] The said individual movements of the wire guide nozzle 34 in relation to the pole horns 16 to be wound are performed sequentially until the complete winding 20 has been constructed upon the pole horn 16.

[0041]FIG. 8 shows the traversing movements of the wire guide nozzle 34 in the horizontal direction x. These traversing movements are produced by the sliding movement of the adjusting blocks 42 along the second guide rails 44. A first traversing movement v1 is made radially outwards in relation to the rotational axis z, a second traversing movement v2 opposes the first traversing movement v1. The traversing movements v1,2 are overlaid with the stroke and indexing movements h1,2 and e1,2 performed perpendicularly thereto. Depending upon the winding speed these movements can be performed continuously to apply uniform winding layers or incrementally to build up a winding layer radially outwards (v1) and subsequently to wind the next layer radially inwards (v2).

[0042] Although the embodiment example shown in FIGS. 1 to 8 shows a winding machine for the winding of stators for internal rotor motors, consideration of the drawing will also lead to the use of the winding machine for the winding of stators for external rotor motors. The functional mode of operation of the individual machine elements remains the same, only their arrangement and orientation in relation to the stator to be wound must be altered.

[0043] For the simultaneous winding of one pole horn each of several stators, three stators for example are arranged in line. Each stator is assigned a bracket with a wire guide. The brackets and wire guides arranged parallel to each other are also actively connected by a common winding rod. 

1. Device for winding wire (36) around pole horns (16) of a rotationally symmetrical multipole stator (12) of an electrical machine, with a wire guide (34) for the supply of the wire (36) and for performing a winding movement made up of individual movements around the pole horn (16) to be wound and a traversing movement in the longitudinal direction of the pole horn (16), characterized in that to perform a first traversing movement in a first direction (z), the wire guide (34) is actively connected to a winding rod (60) which is axially movable in the first direction (z), to perform a second traversing or rotational movement in a second direction (y), an indexing device (28) is actively connected to the stator (12) to be wound, and to perform the traversing movement in a third direction (x) corresponding to the longitudinal direction of the pole horn (16) to be wound, the wire guide (34) is connected to a bracket (32) which is movable in the third direction (x).
 2. Device according to claim 1, characterized in that the bracket (32) is movable in the third direction (x) by means of a second guide (44).
 3. Device according to claim 2, characterized in that a first threaded spindle (46) is provided for the performance of the traversing movement.
 4. Device according to claim 3, characterized in that the first threaded spindle (46) is connected with a first drive motor (56) by means of a preferably flexible shaft (52).
 5. Device according to claim 4, characterized in that the bracket (32) is attached to an adjusting block (42) which is movable along the second guide (44).
 6. Device according to claim 5, characterized in that the bracket (32) is movable in the first direction (z) along a first guide (40) arranged on the adjusting block (42), and the first threaded spindle (46) engages the adjusting block (42).
 7. Device according to claim 6, characterized in that a mounting piece (66) with a slot (68) lying in the third direction (x) is arranged on the winding rod (60) and a guide pin (72) which is attached to the bracket (32) is guided in the slot (68).
 8. Device according to claim 7, characterized in that the winding rod (60) is connected to a second drive motor (64) preferably by means of a second threaded spindle (62).
 9. Device according to claim 8, characterized in that during the winding process the indexing device (28) is connected to a clamping device (22) for the stator (12) to be wound.
 10. Device according to claim 9, characterized in that for the simultaneous winding of several pole horns (16) of a stator (12), several brackets (42) are arranged each with a wire guide (34), the winding rod (60) engages each of the brackets (42) and the brackets (32) can be moved synchronously by means of a first common drive motor (52).
 11. Device according to claim 9, characterized in that for the simultaneous winding of one pole horn (16) each of several stators (12), several brackets (42) are arranged each with a wire guide (34), the winding rod (60) engages each of the brackets (42) and the brackets (32) can be moved synchronously by means of a first common drive motor (52)
 12. Device according to claim 11, characterized in that the brackets (42) with the wire guide (34) are arranged parallel to one another and in line. 